Expandable Boundary Layer Turbine

ABSTRACT

A boundary layer turbine that uses flat disks that can be precision cut at low cost is more cost-effective to construct and maintain than conventional turbines. Bolt-on hub design significantly decreases breakage and distortion. Delta-wing shaped center spacers and flow enhancing, teardrop-shaped outer spacers further increase durability by providing improved support for the disks while minimizing the disturbance of the natural flow of fluids. Use of endplates with heavy outer rims results in turbines with greater gyroscopic effect and greater mass for kinetic energy storage. A disk-directed inlet valve and focused inlet nozzle system increases efficiency by directing flows to the individual disks valve in a low friction containment case. The directed flow tuned inlet nozzle system further increases efficiency. Coating the inner case of the turbine&#39;s enclosure with Teflon or similar materials reduces friction and further improves efficiency.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 61/824,829 filed on May 17, 2013 by David Allan Ryker and Clyde Igarashi, entitled Expandable Boundary Layer Turbine With Bolt-on Hubs, Center Support Spacers, Directed Stream Inlet Valve, and Gyro Endplates; which is hereby incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is generally in the field of boundary layer turbines. More specifically, the present invention teaches a low-cost boundary layer turbine comprising a bolt-on hub and directed-flow tuned inlet nozzle design that significantly decreases breakage and distortion and increases the efficiency of the system.

2. Background Art

Conventional turbine blades are expensive to construct because of their complexity and level of detail. The complexity also adds to fragility and the exposed blades make them prone to breakage, increasing maintenance cost and decreasing dependability. Nikola Tesla's boundary layer turbine employed a simpler design but did not gain widespread application at the time of its invention in part due to limitations of metallurgical technology. Subsequent attempts by experimenters have failed to produce a turbine of significant capacity and durability because they follow the original concept with a large hole through the center, thereby weakening the structure and leaving the disks susceptible to distortion and breakage. Recent experiments have been limited to smaller boundary layer turbines with limited water or air pressure applied. Because of the limitations of the experiments, there is also a question of the efficiency of the turbines.

Conventional turbines are costly to manufacture and maintain, due largely to the fragile nature of their blades. The open blade design leaves them vulnerable to damage. Boundary layer turbines in the past have been susceptible to breakage and distortion, and thus efficiency numbers have been questionable and difficult to verify.

SUMMARY OF THE INVENTION

This invention provides a method to construct a boundary layer turbine that is much cheaper to construct and maintain than conventional turbines because it uses flat disks that can be precision cut at low cost. The design of this invention is an improvement over previous boundary layer turbines because the bolt-on hub design significantly decreases breakage and distortion. Delta-wing shaped center spacers and teardrop shaped outer spacers further increases durability by providing improved support for the disks while minimizing the disturbance of the natural flow of fluids. The use of endplates with heavy outer rims results in turbines with greater gyroscopic effect and greater mass for kinetic energy storage. The focused inlet nozzle system increases efficiency by directing flows to the individual disks. Coating the inner case of the turbine's enclosure with Teflon or similar materials will reduce friction and further improve efficiency.

As stated above, conventional turbine blades are expensive to construct because of their complexity and level of detail. The complexity also adds to fragility and the exposed blades make them prone to breakage, increasing maintenance cost and decreasing dependability. Nikola Tesla turbine's employed a simpler design but did not gain widespread application at the time of its invention in part due to limitations of metallurgical technology. Subsequent attempts by experimenters have failed to produce a turbine of significant capacity and durability because they follow the original concept with a large hole through the center, thereby weakening the structure and leaving the disks susceptible to distortion and breakage. Recent experiments have been limited to smaller boundary layer turbines with limited water or air pressure applied. Because of the limitations of the experiments, there is also a question of the efficiency of the turbines. The invention claimed here solves this problem.

By bolting on hubs directly to disks and not putting a hole through the middle of them, this invention is much stronger and less susceptible to distortions and breakage. Furthermore the delta wing shaped center spacers and teardrop shaped outer spacers in this invention improve support for the disks while minimizing the disturbance of the natural flow of fluids. The use of endplates with heavy outer rims results in turbines with greater gyroscopic effects and greater mass for kinetic energy return. The tuned inlet nozzle system within the containment case with directed streams going to each individual disk increases the efficiency of the system. Coating the inner case of the turbine's enclosure with Teflon or similar materials will reduce friction and further improve efficiency.

The present invention differs from existing prior art because of its simple design. The expandable turbine is much cheaper to build and maintain than a conventional turbine, while also being less fragile.

The present invention provides a method to construct a boundary layer turbine that is much cheaper to construct and maintain than conventional turbines because it uses flat disks that can be precision cut at low cost. The design of this invention is an improvement over previous boundary layer turbines because the bolt-on hub design significantly decreases breakage and distortion. Delta wing shaped center spacers and teardrop shaped outer spacers provide improved support for the disks while minimizing the disturbance of the natural flow of fluids. The use of endplates with heavy outer rims results in turbines with greater gyroscopic effects and greater mass for kinetic energy storage. The directed-flow tuned inlet nozzle system further increases efficiency. Coating the inner case of the turbine's enclosure with Teflon or similar materials will reduce friction and further improve efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a single precision cut disk with laser cutouts with no hole in the very center of the disk.

FIG. 2 illustrates a laser cut disk with the precision cutouts with overlay of delta wing shaped center spacers.

FIG. 3 illustrates a side view of the completed disk pack with hubs bolted on, and outline of delta wing shaped center spacers.

FIG. 4 illustrates a tuned inlet nozzle for fluids including liquids, gases and steam.

FIG. 5 illustrates a casing with inlets and outlets for a six disk turbine.

FIG. 6 illustrates a completed unit from the outside.

FIG. 7 illustrates a stack of disks, endplates with heavy outer rim and bolt-on hubs.

FIG. 8 illustrates a top and side view of a two-piece heavy outer rim with side view of bolt-on hub.

FIG. 9 illustrates teardrop shaped spacers facilitating unimpeded flow of fluids.

FIG. 10 illustrates a disk pack with hubs bolted on, and outline of modified triangle center spacers.

FIG. 11 illustrates a disk with the precision cutouts and delta wing shaped center spacers designed to reduce the number of support bolts in the inner rim of the turbine.

FIG. 12 illustrates a disk with precision cutouts and rounded delta wing shaped center spacers designed to eliminate support bolts on the inner rim of the turbine.

DETAILED DESCRIPTION OF THE INVENTION

The present invention pertains to a low-cost boundary layer turbine comprising a bolt-on hub and directed-flow tuned inlet nozzle design that significantly decreases breakage and distortion and increases the efficiency of the system. The following description contains specific information pertaining to various embodiments and implementations of the invention. Furthermore, the present specification need not represent some of the specific details of the present invention in order to not obscure the invention. A person of ordinary skill in the art would have knowledge of such specific details not described in the present specification. Others may omit or only partially implement some features of the present invention and remain well within the scope and spirit of the present invention.

The following drawings and their accompanying detailed description apply as merely exemplary and not restrictive embodiments of the invention. To maintain brevity, the present specification has not exhaustively described all other embodiments of the invention that use the principles of the present invention and has not exhaustively illustrated all other embodiments in the present drawings.

FIG. 1 illustrates a single precision cut disk 100 with laser cutouts 101 with no hole in the very center of the disk 100.

FIG. 2 illustrates a laser cut disk 100 with the precision cutouts 101 with overlay of delta wing shaped center spacers 200. The center spacers 200 fully support the inner portion of the disks 100. When the tips of the spacers 200 extend beyond the cutout section as pictured in FIG. 2, they aid in initiating movement of the turbine.

FIG. 3 illustrates a side view of the completed disk pack 300 with hubs 301 bolted on, and outline of delta wing shaped center spacers 200. Use of bolts and spacers 302 on the outer and inner rim provide additional support while also aiding in initiating movement of the turbine. The placement and number of bolts and spacers 302 can be varied. Hubs 301 are bolted on each side without an axle going through the center.

FIG. 4 illustrates a tuned inlet nozzle 402 for fluids including liquids, gases and steam. Smaller tubes 402 are placed within a larger tube 401 to direct the flow of fluids between turbine disks 100 and endplates 403. As depicted in a strictly exemplary manner in FIG. 4, eight tubes 402 with endpoints placed between seven disks 100 and two endplates 403. The edges of the disks 100 are sharpened for improved flow. A design embodying any number of tubes 402 or larger tubes 401 clearly remains within the scope and spirit of the present invention.

FIG. 5 illustrates a casing 500 with inlets 402 and outlets 501 for a six-disk 100 turbine. The fluids 502 follow a natural course from the inlets 402 to the center and out through the outlets 501.

FIG. 6 illustrates a completed unit from the outside. Fluids 502 are injected into the outer periphery of the disks 100 then follow a natural path and exit through center.

FIG. 7 illustrates a stack of disks, endplates 403 with heavy outer rim 701 and bolt-on hubs 301. The heavy outer rim 701 facilitates a greater gyroscopic effect and greater potential for kinetic energy storage.

FIG. 8 illustrates a top view 801 and side view 800 of a two-piece heavy outer rim 701 with side view of bolt-on hub 301.

FIG. 9 illustrates teardrop shaped spacers 901 facilitating unimpeded flow of fluids 502.

FIG. 10 illustrates a disk pack 300 with hubs 301 bolted on, and outline of modified triangle center spacers 1001.

FIG. 11 illustrates a disk 100 with the precision cutouts 101 and delta wing shaped center spacers 200 designed to reduce the number of support bolts 302 in the inner rim of the turbine. One bolt 302 goes through each of the three points of the delta wing shaped spacers 200 near the tips.

FIG. 12 illustrates a disk 100 with precision cutouts 101 and rounded delta wing shaped center spacers 1201 designed to eliminate support bolts on the inner rim of the turbine. Support bolts 302 are placed inside the center cutout 101 area instead. This further facilitates the unimpeded flow of fluids 502.

Relationship Between the Components:

Precision cut turbine disks 100 and endplates 403 have no axle going though a hole in the center, but instead use hubs 301 that are bolted 302 on to the sides. The number of disks 100 and spacers 200 should be varied depending on need, along with the size of the bolts 302. Endplates 403 with heavy outer rims 701 would result in greater gyroscopic effect and the potential for greater kinetic energy storage. The delta wing shaped center spacers 200 are placed in between the endplates 403 and disks 100 to fully support the whole inner portion of the disks 100. When the ends of the spacers 200 extend beyond the cutout section 101, they aid in initiating movement by incorporating elements of an impulse turbine. Teardrop shaped spacers 901 can be used with bolts 302 on the outer and inner rim of the disks 100 to provide support, and to facilitate the streaming of fluids 502 from the outer portions of the disks 100 to proceed towards the cutout 101 section unimpeded. The turbine assembly is placed in a low friction case 500 with a tuned inlet nozzle 402 system that directs streams of fluid 502 in between the each of the disks 100 and endplates 403. The low-friction inner case 500 keeps the propelled fluid 502 in a spiral vortex that is eventually expelled through the center cutout 101 of the turbine disks 100. The fluids 502 exit through the exhaust system.

How the Invention Works:

The hubs 301 with low friction bearings are bolted on to the laser cutout endplates 403, with disks 100 and spacers 200 in between. Using endplates 403 with heavy outer rims 701 would result in greater gyroscopic forces and the potential for greater kinetic energy storage. The turbine assembly is housed in a case 500 that is polished or coated with a low friction coating such as Teflon to reduce any resistance. A tuned inlet nozzle 402 system within the containment case 500 directs fluid 502 to the outer edges of each individual disk for improved efficacy. The edges of the disks 100 can be sharpened for improved flow. Bolts and spacers on the outer and inner rim support the disks 100, and aid in initiating movement of the turbine. The fluids 502 pass the spacers 200 on the outer and inner rim of the disks 100 and flow towards the center cutout 101 section, which are supported by the delta wing spacers 200. As the fluids 502 spiral in a vortex, the disk 100 rotates and accelerates in speed, providing the power and torque for useful work. The fluid 502 exits through the outlet nozzles 402. When connected to a generator, this invention can be used to convert any flow of fluids 502 into electricity. The turbine can be used with geothermal steam, water current, or as a wind turbine to capture wind current. Steam can be produced by solar mirrors in combination with fluids 502 and used to power the turbine. The emissions from smokestacks can also be used. Because this invention can use a combination of fluids 502, the possible applications are numerous.

How to Make the Invention:

Disks 100 and spacers 200 should be precision cut. The disks 100 can be constructed of steel, any high strength material or combinations of high strength materials and cut for high precision and balance. Laser cutting or the most advanced cutting technique available should be employed to achieve a high polished surface to enhance natural cohesion with fluids 502. Epoxy resin and metal powders could also be used or any combination thereof. The edges of the disks 100 can be sharpened for more precise flow. The endplates 403 should also be precision cut using the same process but should be thicker than the inside disks 100. The outside edge of the endplates 403 should be sharpened on the side facing the disks 100 and coated with a low friction material on the outside. The bolt-on hubs 301 should use bearings with the least amount of friction possible. There are no holes in the center of the disks 100 or endplates 403 to improve the durability of disks 100 and endplates 403. Disks 100 are precision cut and drilled. This is a low-cost, simple bolt-together assembly. It is expandable by changing the length of bolts and adding more disks 100 and spacers 200. Bolts 302 and spacers 200 on the outer and inner rim provide support for the disks 100, and aid in initiating movement of the turbine by incorporating elements of an impulse turbine. The outer spacers 200 can be round or teardrop shaped 901 for improved flow. The delta wing shaped center spacers 200 fully support the center cut out portion of the disks 100 because they are the same shape in the shared areas. The center spacers 200 should also be precision cut and drilled. When the tips of the delta wing shaped center spacers 200 extend beyond the cutout 101 section, they also aid in initiating movement of the turbine by incorporating elements of an impulse turbine. A low friction outer containment case 500 and exhaust system can be machined or precision cut. The inside of the case 500 should be polished or coated with a low friction material such as Teflon for improved circulation. The tuned inlet nozzle 402 system within the containment case 500 can be made out of steel, copper, similar material. The individual tubes should be placed so that they will direct fluids 502 in between each of the disks 100 and endplates.

More than one expandable turbine can be used together in a multi-stage system or in a closed loop. The delta wing shape spacer 200, while being simple and efficient can be substituted with a modified triangle shape, star shape, star of David shape, or any other similar spacing support 200. Rounds spacers 200 can be used with bolts 302 on the outer and inner rim of the disks 100 instead of teardrop shaped spacers 901.

How to Use the Invention:

The bolt-on hub 301 design with no hole through the middle makes this invention much stronger than a standard Tesla turbine and less susceptible to distortion and breakage. Sharpening the edges of disk and inner portion of the endplates 403 will improve the flow of fluids 502. The delta wing shaped center spacers 200 provide improved support for the inner portion of the disks 100 without disturbing the natural flow of the fluid 502, while the teardrop shaped spacers 901 support outer portion of the disks 100. A low friction containment case 500 reduces resistance. The tuned inlet nozzle 402 within the containment case 500, with directed streams going to each individual disks 100 further increases efficacy. The major components of this invention can be precision laser cut by using CNC machines or similar methods, making it much cheaper to construct and maintain than conventional turbines. The disks 100 and endplates 403 are simple flat disks that are very sturdy. If any individual disk is damaged, it can be simply replaced at low cost. The thicker endplates 403 protect the disks 100 from exposure. Endplates 403 can also be made with a heavy outer rim 701 for greater gyroscopic effect and kinetic energy storage potential.

Additionally: Like the Tesla turbine, the expandable turbine can be used as a pump by expanding the distance between disks 100. The turbines can also be used as gyroscopes, and can be placed in gimbals. They can also be used as flywheels. When used in pairs and counter rotated, rotational bias can be cancelled out. The turbines can be used as a water jet for water craft of all types including jet skis or jet boats or any pressure type water system.

Thus, an Expandable Boundary Layer Turbine has been described. 

What is claimed is:
 1. A boundary layer turbine comprising a fluid from which to extract useful work, said fluid including but not limited to steam, gas, liquid, air, water, wind or water currents, or emissions from smokestacks; whereby said fluid rotates one or plural disks within said turbine due to cohesion of said fluid to said one or plural disks; wherein holes, from which said fluid exits endplates or exits said one or plural disks, are not centered in said endplates nor centered in said one or plural disks.
 2. The boundary layer turbine of claim 1 further comprising a focused inlet nozzle system that increases efficiency by directing flows of said fluid to said one or plural disks.
 3. The boundary layer turbine of claim 1 wherein edges of said one or plural disks or inner portion of said endplates are sharpened for improved flow of said fluid.
 4. The boundary layer turbine of claim 1 wherein said one or plural disks are bolted together with spacers.
 5. The boundary layer turbine of claim 4 wherein said bolts and spacers are located on an outer and inner rim of said one or plural disks to provide support for said one or plural disks and aid in initiating movement of said turbine by incorporating elements of an impulse turbine.
 6. The boundary layer turbine of claim 4 wherein said spacers are delta-wing shaped center spacers or teardrop shaped outer spacers to further increase durability by providing improved support for said one or plural disks while minimizing the disturbance of the natural flow of said fluid.
 7. The boundary layer turbine of claim 4 wherein said turbine is expandable by changing a length of said bolts and adding more said disks and more said spacers.
 8. The boundary layer turbine of claim 7 wherein more than one said expandable turbine can be used together in a multi-stage system or in a closed loop.
 9. The boundary layer turbine of claim 7 wherein said expandable turbine can be used as a pump by expanding the distance between said disks.
 10. The boundary layer turbine of claim 7 wherein said expandable turbine can be used as a water jet for water craft of all types including jet skis or jet boats or any pressure type water system.
 11. The boundary layer turbine of claim 7 wherein said expandable turbine can be used as a gyroscope and can be placed in gimbals.
 12. The boundary layer turbine of claim 7 wherein said expandable turbine can be used as a flywheel.
 13. The boundary layer turbine of claim 12 wherein said expandable turbine is paired and said pair of expandable turbines mutually counter-rotated thereby canceling-out rotational bias.
 14. The boundary layer turbine of claim 12 wherein said endplates comprise heavy outer rims resulting in said turbine having greater gyroscopic effect and greater mass for kinetic energy storage.
 15. The boundary layer turbine of claim 1 wherein hubs are bolted directly onto said one or plural disks without a hole through the center of said one or plural disks to reduce susceptibility to distortions and breakage of said one or plural disks.
 16. The boundary layer turbine of claim 1 wherein an inner case of an enclosure of said turbine is coated with Teflon or similar materials to reduce friction thereby further improving efficiency.
 17. A method of constructing a boundary layer turbine comprising a first step of precision cutting one or plural flat at low cost; wherein said one or plural flat disks are precision laser cut by CNC machines; wherein holes are not centered in said one or plural disks.
 18. The method of claim 17 further comprising a subsequent step wherein edges of said one or plural disks or inner portion of said endplates are sharpened.
 19. The method of claim 17 further comprising a subsequent step wherein said one or plural disks are bolted together with spacers.
 20. The method of claim 17 further comprising a subsequent step wherein hubs are bolted directly onto said one or plural disks without a hole through the center of said one or plural disks. 